EP2036715B1 - Methods and systems for fabrication of composite armor laminates by preform stitching - Google Patents
Methods and systems for fabrication of composite armor laminates by preform stitching Download PDFInfo
- Publication number
- EP2036715B1 EP2036715B1 EP08016353A EP08016353A EP2036715B1 EP 2036715 B1 EP2036715 B1 EP 2036715B1 EP 08016353 A EP08016353 A EP 08016353A EP 08016353 A EP08016353 A EP 08016353A EP 2036715 B1 EP2036715 B1 EP 2036715B1
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- Prior art keywords
- preform
- face sheet
- face
- accordance
- tile
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Links
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- 239000002131 composite material Substances 0.000 title description 20
- 238000004519 manufacturing process Methods 0.000 title description 2
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- 239000011347 resin Substances 0.000 claims description 10
- 229920005989 resin Polymers 0.000 claims description 10
- 229920000049 Carbon (fiber) Polymers 0.000 claims description 6
- 239000004593 Epoxy Substances 0.000 claims description 6
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 5
- 229910052799 carbon Inorganic materials 0.000 claims description 5
- 230000008878 coupling Effects 0.000 claims description 5
- 238000010168 coupling process Methods 0.000 claims description 5
- 238000005859 coupling reaction Methods 0.000 claims description 5
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims description 5
- 210000003371 toe Anatomy 0.000 claims description 4
- 239000000853 adhesive Substances 0.000 claims description 3
- 230000001070 adhesive effect Effects 0.000 claims description 3
- 239000000919 ceramic Substances 0.000 claims description 3
- 230000000295 complement effect Effects 0.000 claims description 3
- 210000001255 hallux Anatomy 0.000 claims 1
- 210000000453 second toe Anatomy 0.000 claims 1
- 238000007493 shaping process Methods 0.000 claims 1
- 239000000835 fiber Substances 0.000 description 12
- 239000004744 fabric Substances 0.000 description 5
- 238000010521 absorption reaction Methods 0.000 description 4
- 239000004917 carbon fiber Substances 0.000 description 4
- 230000013011 mating Effects 0.000 description 2
- 125000006850 spacer group Chemical group 0.000 description 2
- 238000001721 transfer moulding Methods 0.000 description 2
- 229910052580 B4C Inorganic materials 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
- 239000004760 aramid Substances 0.000 description 1
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- INAHAJYZKVIDIZ-UHFFFAOYSA-N boron carbide Chemical compound B12B3B4C32B41 INAHAJYZKVIDIZ-UHFFFAOYSA-N 0.000 description 1
- 229910010293 ceramic material Inorganic materials 0.000 description 1
- 238000005474 detonation Methods 0.000 description 1
- 239000002360 explosive Substances 0.000 description 1
- 239000011152 fibreglass Substances 0.000 description 1
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- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
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Images
Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F41—WEAPONS
- F41H—ARMOUR; ARMOURED TURRETS; ARMOURED OR ARMED VEHICLES; MEANS OF ATTACK OR DEFENCE, e.g. CAMOUFLAGE, IN GENERAL
- F41H5/00—Armour; Armour plates
- F41H5/02—Plate construction
- F41H5/04—Plate construction composed of more than one layer
- F41H5/0492—Layered armour containing hard elements, e.g. plates, spheres, rods, separated from each other, the elements being connected to a further flexible layer or being embedded in a plastics or an elastomer matrix
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F41—WEAPONS
- F41H—ARMOUR; ARMOURED TURRETS; ARMOURED OR ARMED VEHICLES; MEANS OF ATTACK OR DEFENCE, e.g. CAMOUFLAGE, IN GENERAL
- F41H5/00—Armour; Armour plates
- F41H5/02—Plate construction
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F41—WEAPONS
- F41H—ARMOUR; ARMOURED TURRETS; ARMOURED OR ARMED VEHICLES; MEANS OF ATTACK OR DEFENCE, e.g. CAMOUFLAGE, IN GENERAL
- F41H5/00—Armour; Armour plates
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F41—WEAPONS
- F41H—ARMOUR; ARMOURED TURRETS; ARMOURED OR ARMED VEHICLES; MEANS OF ATTACK OR DEFENCE, e.g. CAMOUFLAGE, IN GENERAL
- F41H5/00—Armour; Armour plates
- F41H5/02—Plate construction
- F41H5/04—Plate construction composed of more than one layer
- F41H5/0414—Layered armour containing ceramic material
- F41H5/0428—Ceramic layers in combination with additional layers made of fibres, fabrics or plastics
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/4998—Combined manufacture including applying or shaping of fluent material
- Y10T29/49993—Filling of opening
Definitions
- Embodiments of the disclosure relate generally to composite armor laminates and more particularly, to methods and systems for fabricating composite armor laminates.
- a composite armor for a vehicle is e.g. known from WO 98/37376 A1 .
- At least some known armor systems include a dense ceramic tile enclosed in a supporting structure such as a composite sheet material.
- the ceramic tile is positioned within the supporting structure to receive ballistic missiles and substantially prevent the missile from passing through the armor system and into an occupied cabin of the vehicle.
- one or more tiles may be directly impacted by the missile and other adjacent tiles not directly impacted by the missile may impart forces onto adjacent tiles.
- a composite spacer positioned between the tiles may limit the amount of damage to the adjacent tiles by absorbing at least a portion of the forces imparted by the tiles that were directly impacted by the missile.
- the composite spacer is positioned between tiles manually during layout of the armor system components. This process is time consuming and manual labor intensive.
- an armor system in one embodiment, includes a first face sheet and a shaped preform extending from the first face sheet.
- the preform includes a first edge proximate the first face sheet, a sidewall extending from the first edge to a flange extending substantially perpendicularly from the sidewall.
- the preform circumscribes an area of the first face sheet.
- the system also includes a tile of armor material complementarily-shaped to fit within the area circumscribed by the preform. The tile is positioned within the preform such that at least a portion of the tile is between the first face sheet and the flange.
- the system includes a second face sheet covering the preform and the tile on a side opposite from the first face sheet.
- a method of forming a ballistic resistant armor laminate includes providing a first face sheet and at least one of forming an integral preform with the first face sheet and coupling a shaped preform to the first face sheet wherein the preform extends from a face of the first face sheet to a distal edge and wherein the preform circumscribes an area of the face.
- the method also includes positioning a tile of armor material within the area circumscribed by the preform, forming a flange from the distal edge of the preform wherein at least a portion of a toe of the flange extends substantially parallel to the face and covers at least a portion of the tile, and coupling a second face sheet to the flange to such that the preform and tile are sandwiched between the first and second face sheets.
- an armored vehicle in yet another embodiment, includes a vehicle hull and an armor system covering at least a portion of the hull.
- the armor system includes a plurality of face sheets parallelly oriented with respect to each other and a shaped preform extending from a face of a first of the plurality of face sheets to a face of an adjacent second of the plurality of face sheets, the preform joining the first and the second face sheets.
- the vehicle also includes a plurality of tiles of armor material sandwiched between the first and the second sheets and the preform.
- Figure 1 is a perspective view of an exemplary preform in accordance with an embodiment of the present invention.
- Figure 2 is a perspective view of a partially assembled armor system that may be used with preform shown in Figure 1 ;
- Figure 3 is another perspective view of partially assembled armor system shown in Figure 2 ;
- Figure 4 is a longitudinal cross-section view of a segment of preform that may be used with system shown in Figure 2 .
- Figure 5 is a perspective view of the exemplary armor system shown in Figures 1-4 ;
- Figure 6 is a perspective view of a light weight high mobility vehicle that includes a hull.
- Figure 1 is a perspective view of an exemplary preform 100 in accordance with an embodiment of the present invention.
- Preform 100 includes a sidewall 102 that is configurable to a plurality of different shapes.
- Preform 100 is illustrated in Figure 1 in a hexagonal shape, but any shape or amorphous contour is contemplated.
- Perform 100 is formed in a closed configuration such that a cell 104 is circumscribed by preform 100.
- Preform 100 may include a single cell 104 or may include a plurality of cells.
- cells 104 are sized and shaped complementary to a predetermined size and shape of a tile of armor material to be received therein.
- preform 100 is formed from a web of material in a desired shape.
- preform 100 is formed from a continuous composite fiber wound through a form or mandrel (not shown) having the desired shape.
- a number of passes or turns of the continuous composite fiber that are channeled through each leg of the cell is determined based on a force absorption or strength requirement of the preform.
- the continuous composite fiber may comprise, but is not limited to a carbon fiber, a fiber glass fiber, an aromatic polyamide fiber such as AramidTM, other fiber filaments or combinations thereof.
- the continuous composite fiber may also comprise, but is not limited to, a thread, a tow, or a web comprising the above materials.
- the fiber, web, or tow may be impregnated with an adhesive, a thermoplastic, or a thermoset.
- sidewall 102 includes a first edge 106, a second edge 108, and a sidewall 110 extending therebetween.
- each of edges 106 and 108 include a flange 112 extending substantially perpendicularly away from sidewall 110.
- flange 112 comprises a single toe extending from one or both of edges 106 and 108, in other embodiments, flange 112 comprises a pair of toes extending in opposite direction from one or both of edges 106 and 108.
- preform 100 is a rigid freestanding body.
- preform 100 is a fiber or fabric form that is flexible.
- the fiber or fabric may comprise dry carbon, carbon fiber impregnated with an epoxy or resin, or various combinations thereof.
- FIG 2 is a perspective view of a partially assembled armor system 200 that may be used with preform 100 (shown in Figure 1 ).
- System 200 includes a face sheet 202 that includes a length 204, and width 206, and a thickness 208. Although illustrated in Figure 2 as being substantially rectangular, face sheet 202 may be any shape including regular and irregular shapes.
- preform 100 is integrally formed with face sheet 202.
- Preform 100 is woven with face sheet 202 or is otherwise formed with face sheet 202.
- Face sheet 202 may comprise woven carbon fibers, carbon fiber sheet or fabric.
- Face sheet 202 may comprise dry fabric for infusion of resin or epoxy using a vacuum process such as but not limited to a vacuum-assisted resin transfer molding (VARTM) process.
- Face sheet 202 may also include a fiber such as carbon pre-impregnated with for example but not limited to resin, epoxy or combinations thereof.
- VARTM vacuum-assisted resin transfer molding
- System 200 includes one or more armor tiles 210 within cells 104 in complementary mating engagement.
- cells 104 are substantially hexagonal in cross-section and tiles 210 are also substantially hexagonal in cross-section.
- Tiles 104 are positioned within cells 104 until all cells are filled with tiles 210.
- armor tiles 210 comprise a ceramic material for example, but not limited to boron carbide, silicon carbide, aluminum oxide, and titanium boride.
- Each armor tile 210 includes perimeter surface portions 212 for mating juxtaposition with perimeter surface portions 212 of adjacent armor tiles 210 through the segments preform 100 that lie between the perimeter surface portions 212 to provide a composite layer of armor capable of withstanding and dissipating large forces, for example, upon ballistic impact and shattering of an adjacent tile. Separation of adjacent tiles 210 by preform 100 facilitates absorption of forces transmitted toward an adjacent tile and facilitates dispersing the forces towards other tiles.
- Figure 3 is another perspective view of partially assembled armor system 200 (shown in Figure 2 ).
- system 200 includes a second face sheet 300 coupled to preform 100.
- Second face sheet 300 is substantially similar to first face sheet 202, however second face sheet 300 may include differences from first face sheet 202 in various embodiments.
- preform 100 is formed integrally with first face sheet 202.
- face sheets 202 and 300 may comprise different materials to permit optimum performance for their respective roles.
- face sheet 202 may be exposed to weather or the elements to a greater degree than face sheet 300 because of the orientation of system 200 on a vehicle.
- Face sheet 202 may require a greater UV, abrasion, and chemical resistance than face sheet 300.
- face sheet 300 is coupled to preform 100 through flanges 112 extending from second edge 108 using stitching 302.
- face sheet 300 is coupled to flanges 112 using an adhesive.
- Figure 4 is a longitudinal cross-section view of a segment 400 of preform 100 that may be used with system 200 (shown in Figure 2 ).
- preform 100 includes first edge 106, second edge 108, sidewall 110, and flanges 112.
- Tile 210 is positioned in abutting relationship with sidewall 110 (gap shown in Figure 4 for clarity) such that a portion of tiles 210 are covered by flanges 112.
- Sidewall 110 tends to provide cushioning and force dissipation between adjacent tiles 210.
- Flange 112 is flexible at second edge 108 such that during installation of tile 210, flange 112 is positioned vertically and when tile 210 is positioned within cell 104, flange 112 is folded perpendicular to sidewall 110 to cover a portion of tile 210. Second face sheet 300 is then coupled to flange 112 using, for example, stitching, or adhesion.
- perform 100 may be substantially rigid or semi-rigid to facilitate positioning tiles 210 within cells 104 automatically using a pick-and-place machine including for example, a robotic arm. After positioning tiles 210 within cells 104, flange 112 is folded down to be substantially flush with tiles 210. Second face sheet 300 is then stitched or otherwise attached to flange 112. If face sheets 202 and 300, and preform 100 are fabricated from dry composite material, system 200 is further infused with a resin or an epoxy using a vacuum process such as, but not limited to a vacuum-assisted resin transfer molding (VARTM) process.
- face sheets 202 and 300, and preform 100 may be formed of a fiber such as carbon pre-impregnated with, for example, but not limited to resin, epoxy or combinations thereof. Further processing includes curing the impregnated carbon components.
- Figure 5 is a perspective view of an exemplary armor system 200. After curing, face sheets 202 and 300, preform 100, and tiles 210 form a rigid composite armor laminate, which may be cut or machined to further match desired dimensions.
- FIG. 6 is a perspective view of a light weight high mobility vehicle 600 that includes a hull 602 mounted on a series of driven wheels 604 or tracks, and turret 606 on hull 602.
- Hull 602 is constructed of steel armor plate 608.
- Composite armor laminate system 200 may be formed to a specific contour of a specific vehicle of area on a vehicle.
- system 200 provides energy absorption from detonation of an explosive missile on an adjacent armor tile through preform 100. Forces applied to tiles adjacent to tiles 210 may be moderated by energy transfer to adjacent tiles through preform 110.
- the above-described methods of fabricating composite armor laminate structures are cost-effective and highly reliable.
- the methods and systems include using a composite preform to facilitate reducing hand labor during the assembly process.
- the preform includes composite fabric or thread that when cured provides strength, absorption of forces between tiles and redirection of forces between tiles to transmit forces over a wider area. Accordingly, the methods and systems facilitate assembly of composite armor laminate systems in a cost-effective and reliable manner.
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- Engineering & Computer Science (AREA)
- General Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Aiming, Guidance, Guns With A Light Source, Armor, Camouflage, And Targets (AREA)
- Laminated Bodies (AREA)
- Moulding By Coating Moulds (AREA)
- Lining Or Joining Of Plastics Or The Like (AREA)
Abstract
Description
- Embodiments of the disclosure relate generally to composite armor laminates and more particularly, to methods and systems for fabricating composite armor laminates. A composite armor for a vehicle is e.g. known from
WO 98/37376 A1 - At least some known armor systems include a dense ceramic tile enclosed in a supporting structure such as a composite sheet material. The ceramic tile is positioned within the supporting structure to receive ballistic missiles and substantially prevent the missile from passing through the armor system and into an occupied cabin of the vehicle. During impact, one or more tiles may be directly impacted by the missile and other adjacent tiles not directly impacted by the missile may impart forces onto adjacent tiles. A composite spacer positioned between the tiles may limit the amount of damage to the adjacent tiles by absorbing at least a portion of the forces imparted by the tiles that were directly impacted by the missile. During assembly of the armor system, the composite spacer is positioned between tiles manually during layout of the armor system components. This process is time consuming and manual labor intensive.
- In one embodiment, an armor system includes a first face sheet and a shaped preform extending from the first face sheet. The preform includes a first edge proximate the first face sheet, a sidewall extending from the first edge to a flange extending substantially perpendicularly from the sidewall. The preform circumscribes an area of the first face sheet. The system also includes a tile of armor material complementarily-shaped to fit within the area circumscribed by the preform. The tile is positioned within the preform such that at least a portion of the tile is between the first face sheet and the flange. The system includes a second face sheet covering the preform and the tile on a side opposite from the first face sheet.
- In another embodiment, a method of forming a ballistic resistant armor laminate includes providing a first face sheet and at least one of forming an integral preform with the first face sheet and coupling a shaped preform to the first face sheet wherein the preform extends from a face of the first face sheet to a distal edge and wherein the preform circumscribes an area of the face. The method also includes positioning a tile of armor material within the area circumscribed by the preform, forming a flange from the distal edge of the preform wherein at least a portion of a toe of the flange extends substantially parallel to the face and covers at least a portion of the tile, and coupling a second face sheet to the flange to such that the preform and tile are sandwiched between the first and second face sheets.
- In yet another embodiment, an armored vehicle includes a vehicle hull and an armor system covering at least a portion of the hull. The armor system includes a plurality of face sheets parallelly oriented with respect to each other and a shaped preform extending from a face of a first of the plurality of face sheets to a face of an adjacent second of the plurality of face sheets, the preform joining the first and the second face sheets. The vehicle also includes a plurality of tiles of armor material sandwiched between the first and the second sheets and the preform.
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Figure 1 is a perspective view of an exemplary preform in accordance with an embodiment of the present invention; -
Figure 2 is a perspective view of a partially assembled armor system that may be used with preform shown inFigure 1 ; -
Figure 3 is another perspective view of partially assembled armor system shown inFigure 2 ; -
Figure 4 is a longitudinal cross-section view of a segment of preform that may be used with system shown inFigure 2 . -
Figure 5 is a perspective view of the exemplary armor system shown inFigures 1-4 ; and -
Figure 6 is a perspective view of a light weight high mobility vehicle that includes a hull. - The following detailed description illustrates the disclosure by way of example. The description clearly enables one skilled in the art to make and use the disclosure, describes several embodiments, adaptations, variations, alternatives, and uses of the disclosure, including what is presently believed to be the best mode of carrying out the disclosure. The disclosure is described as applied to a preferred embodiment, namely, a process of forming composite armor laminates. However, it is contemplated that this disclosure has application to manufacturing components and assemblies where materials may be joined to form larger subsystems of panels and/or sheets that heretofore required significant manual labor to assemble.
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Figure 1 is a perspective view of anexemplary preform 100 in accordance with an embodiment of the present invention.Preform 100 includes asidewall 102 that is configurable to a plurality of different shapes.Preform 100 is illustrated inFigure 1 in a hexagonal shape, but any shape or amorphous contour is contemplated.Perform 100 is formed in a closed configuration such that acell 104 is circumscribed by preform 100. Preform 100 may include asingle cell 104 or may include a plurality of cells. In the exemplary embodiment,cells 104 are sized and shaped complementary to a predetermined size and shape of a tile of armor material to be received therein. In one embodiment,preform 100 is formed from a web of material in a desired shape. In other embodiments,preform 100 is formed from a continuous composite fiber wound through a form or mandrel (not shown) having the desired shape. A number of passes or turns of the continuous composite fiber that are channeled through each leg of the cell is determined based on a force absorption or strength requirement of the preform. The continuous composite fiber may comprise, but is not limited to a carbon fiber, a fiber glass fiber, an aromatic polyamide fiber such as Aramid™, other fiber filaments or combinations thereof. The continuous composite fiber may also comprise, but is not limited to, a thread, a tow, or a web comprising the above materials. The fiber, web, or tow may be impregnated with an adhesive, a thermoplastic, or a thermoset. - In the exemplary embodiment,
sidewall 102 includes afirst edge 106, asecond edge 108, and asidewall 110 extending therebetween. In the exemplary embodiment, each ofedges flange 112 extending substantially perpendicularly away fromsidewall 110. In various embodiments,flange 112 comprises a single toe extending from one or both ofedges flange 112 comprises a pair of toes extending in opposite direction from one or both ofedges - In the exemplary embodiment, preform 100 is a rigid freestanding body. In other embodiments, is a fiber or fabric form that is flexible. The fiber or fabric may comprise dry carbon, carbon fiber impregnated with an epoxy or resin, or various combinations thereof.
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Figure 2 is a perspective view of a partially assembledarmor system 200 that may be used with preform 100 (shown inFigure 1 ).System 200 includes aface sheet 202 that includes alength 204, andwidth 206, and athickness 208. Although illustrated inFigure 2 as being substantially rectangular,face sheet 202 may be any shape including regular and irregular shapes. In the exemplary embodiment,preform 100 is integrally formed withface sheet 202. Preform 100 is woven withface sheet 202 or is otherwise formed withface sheet 202.Face sheet 202 may comprise woven carbon fibers, carbon fiber sheet or fabric.Face sheet 202 may comprise dry fabric for infusion of resin or epoxy using a vacuum process such as but not limited to a vacuum-assisted resin transfer molding (VARTM) process.Face sheet 202 may also include a fiber such as carbon pre-impregnated with for example but not limited to resin, epoxy or combinations thereof. -
System 200 includes one ormore armor tiles 210 withincells 104 in complementary mating engagement. In the exemplary embodiment,cells 104 are substantially hexagonal in cross-section andtiles 210 are also substantially hexagonal in cross-section.Tiles 104 are positioned withincells 104 until all cells are filled withtiles 210. In the exemplary embodiment,armor tiles 210 comprise a ceramic material for example, but not limited to boron carbide, silicon carbide, aluminum oxide, and titanium boride. Eacharmor tile 210 includesperimeter surface portions 212 for mating juxtaposition withperimeter surface portions 212 ofadjacent armor tiles 210 through the segments preform 100 that lie between theperimeter surface portions 212 to provide a composite layer of armor capable of withstanding and dissipating large forces, for example, upon ballistic impact and shattering of an adjacent tile. Separation ofadjacent tiles 210 bypreform 100 facilitates absorption of forces transmitted toward an adjacent tile and facilitates dispersing the forces towards other tiles. -
Figure 3 is another perspective view of partially assembled armor system 200 (shown inFigure 2 ). In the exemplary embodiment,system 200 includes asecond face sheet 300 coupled to preform 100.Second face sheet 300 is substantially similar tofirst face sheet 202, howeversecond face sheet 300 may include differences fromfirst face sheet 202 in various embodiments. For example, in one embodiment, described above,preform 100 is formed integrally withfirst face sheet 202. Moreover, facesheets face sheet 202 may be exposed to weather or the elements to a greater degree thanface sheet 300 because of the orientation ofsystem 200 on a vehicle. Facesheet 202 may require a greater UV, abrasion, and chemical resistance thanface sheet 300. In the exemplary embodiment,face sheet 300 is coupled to preform 100 throughflanges 112 extending fromsecond edge 108 usingstitching 302. In another embodiment,face sheet 300 is coupled toflanges 112 using an adhesive. -
Figure 4 is a longitudinal cross-section view of asegment 400 ofpreform 100 that may be used with system 200 (shown inFigure 2 ). In the exemplary embodiment,preform 100 includesfirst edge 106,second edge 108,sidewall 110, andflanges 112.Tile 210 is positioned in abutting relationship with sidewall 110 (gap shown inFigure 4 for clarity) such that a portion oftiles 210 are covered byflanges 112.Sidewall 110 tends to provide cushioning and force dissipation betweenadjacent tiles 210.Flange 112 is flexible atsecond edge 108 such that during installation oftile 210,flange 112 is positioned vertically and whentile 210 is positioned withincell 104,flange 112 is folded perpendicular to sidewall 110 to cover a portion oftile 210.Second face sheet 300 is then coupled toflange 112 using, for example, stitching, or adhesion. - During assembly, perform 100 may be substantially rigid or semi-rigid to facilitate
positioning tiles 210 withincells 104 automatically using a pick-and-place machine including for example, a robotic arm. After positioningtiles 210 withincells 104,flange 112 is folded down to be substantially flush withtiles 210.Second face sheet 300 is then stitched or otherwise attached toflange 112. Ifface sheets system 200 is further infused with a resin or an epoxy using a vacuum process such as, but not limited to a vacuum-assisted resin transfer molding (VARTM) process. In another embodiment, facesheets -
Figure 5 is a perspective view of anexemplary armor system 200. After curing,face sheets preform 100, andtiles 210 form a rigid composite armor laminate, which may be cut or machined to further match desired dimensions. -
Figure 6 is a perspective view of a light weighthigh mobility vehicle 600 that includes ahull 602 mounted on a series of drivenwheels 604 or tracks, andturret 606 onhull 602.Hull 602 is constructed ofsteel armor plate 608. Compositearmor laminate system 200 may be formed to a specific contour of a specific vehicle of area on a vehicle. In the exemplary embodiment,system 200 provides energy absorption from detonation of an explosive missile on an adjacent armor tile throughpreform 100. Forces applied to tiles adjacent totiles 210 may be moderated by energy transfer to adjacent tiles throughpreform 110. - The above-described methods of fabricating composite armor laminate structures are cost-effective and highly reliable. The methods and systems include using a composite preform to facilitate reducing hand labor during the assembly process. The preform includes composite fabric or thread that when cured provides strength, absorption of forces between tiles and redirection of forces between tiles to transmit forces over a wider area. Accordingly, the methods and systems facilitate assembly of composite armor laminate systems in a cost-effective and reliable manner.
Claims (16)
- An armor system comprising:a first face sheet (202);a preform (100) shaped to receive a tile (210) of armor material, said preform (100) extending from said first face sheet (202), said preform (100) comprising a first edge (106) proximate said first face sheet (202), a sidewall (102) extending from the first edge (106) to a flange (112) extending substantially perpendicularly from said sidewall (102), said preform (100) circumscribing an area of said first face sheet (202);a tile (210) of armor material having a predetermined shape, said tile (210) positioned within said preform (100) such that at least a portion of said tile (210) is between said first face sheet (202) and said flange (112); anda second face sheet (300) covering said preform (100) and said title (210) on a side opposite from said first face sheet (202).
- A system in accordance with Claim 1 wherein said first edge (106) is formed unitarily with said first face sheet (202).
- A system in accordance with Claim 1 or 2 wherein said first edge (106) is coupled to said first face sheet (202) using stitching and/or an adhesive.
- A system in accordance with any of Claims 1-3 wherein at least one of said preform (100), said first face sheet (202), and said second face sheet (300) comprises carbon and epoxy.
- A system in accordance with any of Claims 1-4 wherein said tile (210) comprises ceramic.
- A system in accordance with any of Claims 1-5 wherein said second face sheet (300) is stitched to said preform (100) using said flange (112).
- A system in accordance with any of Claims 1-6 wherein said flange (112) comprises a first and second toe wherein said toes of said flange (112) extend in opposite directions.
- A system in accordance with any of Claims 1-7 wherein said system further comprises resin infused into voids within and between the tile (210), the preform (100), the first face sheet (202), and the second face sheet (300).
- A method of forming a ballistic resistant armor laminate, said method comprising:coupling a second face sheet (300) to the flange (112) to such that the preform (100) and tile (210) are sandwiched between the first and second face sheets (202, 300).
- A method in accordance with Claim 9 further comprising shaping the preform (100) to a size and shape complementary to a predetermined size and shape of the tile (210) of armor material.
- A method in accordance with Claim 9 or 10 further comprising infusing the sandwich with a resin using a vacuum.
- A method in accordance with any of Claims 9-11 wherein at least one of the preform (100), the first face sheet (202) and the second face sheet (300) comprise a resin pre-impregnated carbon fabric and wherein the method further comprises curing the at least one of the preform (100), the first face sheet (202) and the second face sheet (300).
- A method in accordance with any of Claims 9-12 wherein coupling a shaped preform (100) to the first face sheet (202) comprises stitching the preform (100) to the first face sheet (202) and/or coupling a second face sheet (300) to the flange (112) comprises stitching the second face sheet (300) to the flange (112).
- An armored vehicle comprising:a vehicle (600) hull (602); andan armor system, preferably in accordance with any of Claims 1-8, covering at least a portion of the hull (602) said armor system comprising:a plurality of face sheets parallelly oriented with respect to each other;a shaped preform (100) extending from a face of a first of said plurality of face sheets (202) to a face of an adjacent second of said plurality of face sheets (300), said preform (100) joining said first and said second face sheets (202, 300); anda plurality of tiles (210) of armor material sandwiched between said first and said second sheets (202, 300) and said preform (100).
- A vehicle (600) in accordance with Claim 14 wherein said preform comprises a first edge (106) proximate said first face sheet (202), a sidewall (102) extending from the first edge (106) to a flange (112) extending substantially perpendicularly from said sidewall (102), and/or wherein said preform (100) circumscribes at least one tile (210).
- A vehicle (600) in accordance with Claim 14, or 15 wherein said preform (100) comprises a plurality of passes of carbon fabric circumscribing a plurality of tiles (210) and/or wherein said preform (100) is formed integrally with said first face sheet (202).
Applications Claiming Priority (1)
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US11/856,161 US7752955B2 (en) | 2007-09-17 | 2007-09-17 | Methods and systems for fabrication of composite armor laminates by preform stitching |
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EP2036715A1 EP2036715A1 (en) | 2009-03-18 |
EP2036715B1 true EP2036715B1 (en) | 2011-12-28 |
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EP (1) | EP2036715B1 (en) |
JP (1) | JP5319997B2 (en) |
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CA (1) | CA2639444C (en) |
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JP2009068835A (en) | 2009-04-02 |
KR20090029167A (en) | 2009-03-20 |
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US20090072569A1 (en) | 2009-03-19 |
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KR101539766B1 (en) | 2015-07-27 |
ATE538924T1 (en) | 2012-01-15 |
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